Impact of cell cracks on performance of PV modules with current cell technologies

Cracks in photovoltaic modules can affect power output, but their relevance depends on module architecture and operating conditions. This study examines how crack length and crack number relate to power loss in 230 mono-Si mini-modules spanning full-cell PERC and half-cut TOPCon technologies with busbar counts from 2 to 12, focusing exclusively on cell line cracks that do not lead to electrically isolated cell parts. Electroluminescence images were used to quantify crack characteristics and busbars, while current–voltage measurements at 200 W/m 2 and 1000 W/m 2 were used to extract series resistance, shunt resistance, and maximum power point. Correlation analysis was then used to assess how crack characteristics relate to electrical performance. The results show that crack length and crack number are not universal predictors of power loss in modern modules. PERC modules exhibit moderate crack–power correlations at low irradiance, but these correlations weaken at 1000 W/m 2 . TOPCon modules show no meaningful correlation at either irradiance level. The results indicate that crack sensitivity is governed primarily by irradiance, busbar count, and cell architecture, rather than by crack length alone.